Cable insulators

Nylon A class of synthetic fibres and plastics, polyamides. Manufactured by condensation polymerization of ct, oj-aminomonocarboxylic acids or of aliphatic diamines with aliphatic dicarboxylic acids. Also rormed specifically, e.g. from caprolactam. The different Nylons are identified by reference to the carbon numbers of the diacid and diamine (e.g. Nylon 66 is from hexamethylene diamine and adipic acid). Thermoplastic materials with high m.p., insolubility, toughness, impact resistance, low friction. Used in monofilaments, textiles, cables, insulation and in packing materials. U.S. production 1983 11 megatonnes. 

Aryl Phosphates. Aryl phosphates were introduced into commercial use early in the twentieth century for flammable plastics such as cellulose nitrate and later for cellulose acetate. CeUulosics are a significant area of use but are exceeded now by plastici2ed vinyls (93—95). Principal appHcations are in wire and cable insulation, coimectors, automotive interiors, vinyl moisture barriers, plastic greenhouses (Japan), furniture upholstery, conveyer belts (especially in mining), and vinyl foams. 

The relationship of the dielectric constant of the cable insulation to crosstalk can be measured by testing two cables for crosstalk with the same dimension, but different insulation materials. The cable with the lower dielectric constant has less capacitance unbalance, thus resulting in lower crosstalk than the cable with the higher dielectric constant. 

Table 2. Wire and Cable Insulation PVC Formulations, Parts by Weight...

The interface between conductor shield and insulation is the region of the highest stress in the cable insulation stmcture. Any imperfections at this interface, especially sharp protmsions of the conductor shield into the insulation, will cause high local electrical stress that may reduce the dielectric strength of finished cable. Calculation of the stress enhancement, for a 15 kV cable with a 4.4 mm (175 mil) insulation thickness, indicates that the common round 50 p.m (2 mil) radius protmsions increase the electrical stress by a factor of 30 and a sharp 5 fim protmsion will increase the electric stress by as much as 210 times (11,20). 

B. F. Goodrich Co., Typical Properties of Geon Uinyl Compounds for Wire and Cables Insulation and Jacketing, bulletin, Cleveland, Ohio, 1991. 

Electrical Properties. Erom a chemical standpoint, HDPE is a saturated aUphatic hydrocarbon and hence a good insulator. Its electrical characteristics are given in Table 1. Because polymer density and molecular weight affect electrical properties only slightly, HDPE is widely used for wire and cable insulation. 

Because it is a saturated aUphatic hydrocarbon, LLDPE does not conduct electricity, and so is widely used for wire and cable insulation. LLDPE is poorly permeable to water and inorganic gases and only slightly more so to organic compounds, whether Hquid or gas. 

Properties desired in cable insulation and flexible circuit substrate materials include mechanical flexibiUty, fatigue endurance, and resistance to chemicals, water absorption, and abrasion. Both thermoplasts and thermosets are used as cable-insulating materials. Thermoplastic materials possess excellent electrical characteristics and are available at relatively low cost. 

Commonly used materials for cable insulation are poly(vinyl chloride) (PVC) compounds, polyamides, polyethylenes, polypropylenes, polyurethanes, and fluoropolymers. PVC compounds possess high dielectric and mechanical strength, flexibiUty, and resistance to flame, water, and abrasion. Polyethylene and polypropylene are used for high speed appHcations that require a low dielectric constant and low loss tangent. At low temperatures, these materials are stiff but bendable without breaking. They are also resistant to moisture, chemical attack, heat, and abrasion. Table 14 gives the mechanical and electrical properties of materials used for cable insulation. 

Table 14. Mechanical and Electrical Properties of Cable Insulating Materials...

The amount of plasticizer added to the polymer in question varies, depending on the magnitude of the effect required. For example, a small addition of plasticizer may be made simply to improve the workabiUty of the polymer melt. This contrasts with larger additions made with the specific intention of completely transforming the properties of the product. For example, PVC without a plasticizer, ie, unplasticized PVC (PVC-U), is used in appHcations such as pipes and window profiles with plasticizer added, articles such as PVC food film, PVC cable insulation, and sheathing and PVC floorings are formed. 

PVC—nitrile mbber permanent plasticization of PVC, improved processibihty wire and cable insulation, food contact service 141,317,318... 

Electrical Applications. Plastics are used for electrical insulation, conduit and enclosures, lighting fixtures, and mechanical devices. The most widely used plastic for wire and cable insulation is flexible, plasticized PVC, which constitutes well over half the market in insulating wires for buildings, automobiles, appHances, and power and control lines. Polyethylene is also a factor. Higher performance plastics such as nylon and fluoropolymers also play a smaller role in this area. 

The main uses of EPM of EPDM are in automotive appHcations as profiles, (radiator) hoses, and seals in building and constmction as profiles, roofing foil, and seals in cable and wke as cable insulation and jacketing and in appHances as a wide variety of mostiy molded articles. 

Wire and cable insulation based on vulcanizates of PZ has also been studied. Again, low fire risk was the target property, and this was achieved. The need to vulcanize the coating, somewhat modest tensile properties, tensile strength of 5.2 to 12.2 MPa (760 to 1770 psi), and high dielectric constant (4—5 at 10,000 Hz) limited interest in this appHcation (19). 

Check the condition of the cable insulation, its termination and jointing. Motor connections should always be made... 

Irrespective of the system voltage, a CBCT may be designed for an insulation level of only 660 V. The cable insulation of the HT conductor is sufficient to provide the required insulation between the conductor and the CBCT. 

Anode supports, cable insulators and the coating on the object to be protected can be destroyed by anodic evolution of chlorine (see Section 7.1), Only chorine-resistant materials should be used. Anodes on retaining walls or between pile foundations can be installed in perforated or fabricated plastic tubes (half-shells) (see Fig. 16-8). They must naturally be provided with very many holes to avoid uneven removal of anode material. Filter tubes of a chlorine-resistant special material or... 

Interest in EVA as a cable-insulating material has arisen because of the good resistance to stress cracking and because the polymer may be more easily cross-linked (see Table 11.12). 

During the next few years PVC was steadily developed in the United States and in Germany. Both countries were producing the material commercially before World War II. In Great Britain, ICI in 1942 and the Distillers Company in 1943 also commenced pilot-plant production of PVC, a material then in demand as a rubber substitute for cable insulation. Paste-forming grades suitable for the production of leathercloth also became available soon afterwards. 

Certain higher phthalates are also available. For example, ditridecyl phthaiate and di-isodecyl phthaiate are used in high-temperature cable insulation, the former having the better high-temperature properties. Because of its greater hydrocarbon nature than DIOP, di-isodecyl phthaiate has lower water extract-ability and is used, for example, with epoxidised oils in baby-pants. 

The market for PPVC film and sheet is only slightly less than for wire and cable insulation. Uses are as diverse as seepage barriers, factory doors, inflatables, baby pants, car trim, covering materials for book bindings and document cases and shower curtains. UPVC film has also been widely used for packaging of food, particularly for shrink-wrap purposes, but this market has been subject to some substitution by polypropylene. 

This copolymer has proved particularly suitable for wire and cable insulation, with many grades being rated at 155°C for 20 000 h continuous exposure. It is extensively used in electrical systems for aircraft, underground railways, computers, telecommunications installations and heating circuits. Because of its toughness combined with its heat and chemical resistance it also finds use for lining pumps and valves and other equipment for the chemical industry and for laboratory ware. 

Silicone cable insulation is also used extensively in naval craft since the insulation is not destroyed in the event of a fire but forms a protective and insulating layer of silica. 

These materials are developed from the polyetherimides introduced by General Electric (see also Section 18.14.2). At the time of writing one grade, Ultem Siltem STM 1500, is being offered. It is of particular interest as a material for wire and cable insulation, as it not only has excellent flame resistance coupled with low smoke generation but also avoids possible toxic and corrosion hazards of halogenated polymers. This can be of importance where there are possible escape problems in the event of a fire, such as in tunnels, aircraft and marine (particularly submarine) vessels. 

At one time gutta pereha had an important outlet in undersea cable insulation and a lesser use in chemical plant, in particular for storage of hydrofluoric acid. It is now virtually obsolete. 

P Injection, blow, extrusion and rotational Pipe, pipe fittings, surgical implants, coatings, wire and cable insulation... 

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